suspension FORD MUSTANG 1969 Volume One Chassis

03-13-06

Specifications

03-13-06

TORQUE LIMITS-FRONT SUSPENSION

LINCOLN CONTINENTAL

Description

Brace-Front Suspension to Sidemember (Model 74A Only)

Drag Strut
to
Strut Bracket Assembly

Lower Arm Assembly to Front Crossmember
-
(Attach Bracket)

Lower Arm Assembly to No. 2 Crossmember

Drag Strut
to
Lower Arm Assembly

Wheel Spindle to Lower Arm Ball Joint

Front Wheel Spindle to Upper Arm Ball Joint Assembly

Upper Arm Inner Shaft
to
Upper Arm

Upper Arm and Shaft Assembly to No. 2 Crossmember

Shock Absorber Bracket Assembly to No. 2 Crossmember Bracket

Shock Absorber Assembly to No. 2 Crossmember Assembly (Top End)

Shock Absorber Assembly Lower Arm Spring Seat Reinforcement Assembly

Upper Ball Joint
to
Control Arm

Stabilizer Bar Assembly
to
Underbody

Stabilizer Bar
to
Lower Arm

Jounce Bumper Assembly
to
Strut (Lower Arm)

Front Splash Shield to Spindle

Caliper to Spindle
FtLbs

90-110

70-90

55-75

110-140

70-90

70-90

55-75

25-35

100-125

40-55

20-30

20-30

21-29

20-30

5-10

22-28

9-14

100-140

TORQUE LIMITS-REAR SUSPENSION

FORD, MERCURY, METEOR

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm to Axle Bracket (Nut)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torque)

Track Bar Stud to Axle Bracket (Nut)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer to Axle-All Cars except those with 240
or
302 CID Engines

Brake Backing Plate and Bearing Retainer to Axle-All Cars with 240
or
302 CID Engines

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly
to
Frame

Lower Arm to Axle-Bolt

Lower Arm to Axle-Nut

Upper Arm
to
Frame-BoU

Upper Arm
to
Frame-Nut

Lower Arm
to
Frame-Bolt

Lower Arm
to
Frame-Nut

Bumper Assembly to No. 4 Crossmember

Universal Joint
U-Bolt
Nut

Air Leveling Compressor
to
Apron

Height Control Valve to Bracket

Height Control Valve Bracket to No. 4 Crossmember
FtLbs

20-28

90-100

80-105

100-130

80-105

80-105

70-115

50-70

20-30

50-35

9-13

90-120

70-90

90-120

70-90

90-120

70-90

9-13

10-15

10-13

17-25

9-13procarmanuals.com

03-13-07

Specifications

03-13-07

TORQUE LIMITS-REAR SUSPENSION

MONTEGO, FALCON, FAIR LANE, MUSTANG AND COUGAR

Description

Spring Shackle Bars to Body and Spring

Shock Absorber
to
Upper Mounting Bracket

Shock Absorber to Spring Clip Plate

Spring to Axle U-Bolt Nut

Wheel Lug Nut 5-Lug Wheel

Spring to Spring Front Hanger
•
Bolt

Spring to Spring Front Hanger
•
Nut

Universal Joint U-Bolt Nut -Std. Trans.

Universal Joint U-Bolt Nut -Auto. Trans.
Mont
ego,
Falcon, Fair lane

15-22

20-28

20-28

35-50

70-115

90-120

40-60

6-11

10-15
Mustang and Cougar

15-22

20-28

20-28

35-50

70-115

60-85

40-60

6-11

10-15

TORQUE LIMITS-REAR SUSPENSION

LINCOLN CONTINENTAL

Description

Brake Backing Plate Bearing Retainer to Axle

Spring Center Bolt

Spring Front Bracket Assembly to Rear Floor Sidemember Assembly

Spring Front Eye Stud and Washer Assembly to Spring Front Hanger Bracket

Spring U-Bolt

Spring Assembly
to
Spring Shackle Assembly

Spring Shackle Assembly
to
Spring Rear Bracket Assembly

Spring Rear Bracket Assembly
to
Rear Floor Sidemember Assembly

Shock Absorber Upper Attaching Bracket
to
Body Crossmember

Shock Absorber Assembly
to
Shock Absorber Upper Attaching Bracket

Shock Absorber Assembly to Axle

Axle Bumper Bracket
to
Underbody

Pinion Bumper Assembly to Axle Carrier
Ft Lbs

30-55

15-20

70-90

76-106

45-65

34-59

34-59

40-67

20-30

20-28

30-45

10-15

18-25

TORQUE LIMITS-REAR SUSPENSION

THUNDERBIRD, CONTINENTAL.MARK
III

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm
to
Axle (Front)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torqe)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer
to
Axle

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly to Frame

Lower Arm
to
Axle - Bolt

Lower Arm
to
Axle- Nut

Upper Arm
to
Frame -Bolt

Upper Arm
to
Frame
•
Nut

Lower Arm
to
Frame • Bolt

Lower Arm to Frame
-
Nut

Bumper Assembly to No. 4 Crossmember
Ft-Lbs

20-28

70-90

80-105

100-130

70-90

70-115

50-75

50-85

Self-Tapping

90-120

70-80

90-120

70-90

90-120

70-90

Self-Tappingprocarmanuals.com

03-13-08
Specifications
03-13-08

SPECIAL SERVICE TOOLS

Tool No.

T50T-100-A

T59L-100-B

T58L-101-A

T53L-200-A

T62L-201-A

OTC-462

T57L-500-A

T69L-1102-A

Tool 1175-AB

Tool 1175-AH

T56P-1217-A

T60K-1217-A

Tool 1217-J

Tool 1217-K

Tool
1217- L

Tool 1217-M

T65P-3000-A, D

T65P-3000-B, C, E, F

T57P-3006-A

T60K-3005-A

T62F-3006-A

Tool 3044-A

T54P-3044-A

T60K-3044-A

T65P-3044-A

Tool 3068

Tool 3069-AA

Tool
3069-
M

Tool 3290-C

T65P-3524-A

T66P-3553-A, B

T66P-3553-C

T65P-3548-A

T62F-3576-A

T64K-3576-A

T64K-3576-B

T65P-3576-A, B

T65P-3576-C

Tool 3583-J

T65P-3590-F

T67L-3600-A

T65P-3805-A

T63P-5310-A

T64K-5310-A, B

T66P-5310-A, B

T64N-5781-A

T64K-5781-B

Tool 6306-AG

T63L-8620-A

T63L-10300-B

T65P-10300-B

T56L-33610-D

T68L-33610-A

Tool 33623-D

T65P-3A537-A

T65P-3A537-B

T69P-3A674-A

T65P-3A733-A

T65T-3B177-A

T68P-3B586-A

T68P-3B592-A

T68P-3B592-B

T64B-3C716-A

T65P-3C732-A

T65P-3D517-A

T65P-3D525-A

T65P-3D525-B

T65P-3D526-A

T69P-3D608-A

T69P-3D608-B

T65P-3D642-A

T67P-3D739-A
Description

Slide Hammer-Long

Slide Hammer-Short

Puller Attachment

Handle Adapter

Input Shaft Seal Installer

Tie Rod Separator (Owatonna Tool Co.)

Bench Mounted Holding Fixture

Front Wheel Bearing Remover

Grease Seal Remover (Head Only)

Grease Seal Replacer

Front Hub Bearing Cup and Grease Seal Replacer

Front Hub Bearing Cup and Grease Seal Replacer

Front Hub Outer Bearing Cup Replacer

Front Hub Inner Bearing Cup Replacer

Front Hub Outer Bearing Cup Remover

Front Hub Inner Bearing Cup Remover

Adjusting Bars-Caster and Camber

Alignment Spacers

Spindle Ball Joint Remover Press

Spindle Ball Joint Press Adapter Screw

Spindle Ball Joint Press Adapter Screw

Front Suspension Upper Arm Bushing Remover

Front Suspension Upper and Lower Arm Overhaul Kit

Front Suspension Lower Arm Bushing Remover and Replacer

Upper Arm Bushing Overhaul Kit

Front Suspension Upper Arm Bushing Adapter

Front Suspension Lower Arm Bushing Remover

Lower Arm Bushings-Remover and Replacer Kit

Tie Rod Ball Ends and Control Valve Ball Stud Remover

Input Shaft Bearing Remover and Installer

Spanner Wrench

Spacer

Oil Line Connector Seal Installer

Sector Shaft Bushing Remover and Replacer

Sector Shaft Needle Bearings and Seal Remover and Replacer

Sector Shaft Needle Bearings and Seal Remover and Replacer Adapter

Sector Shaft Bushing Remover and Installer

Remover and Installer Adapter

Control Valve Bearing and Seal Remover and Replacer

Steering Pitman Arm Remover

Steering Wheel Remover

Ring Compressor-Rack Piston

Front Coil Spring Remover and Replacer

Adapters

Adapters

Rear Spring Front Bushing Remover and Installer

Rear Spring Bushing Adapter

Crankshaft Damper Remover and Power Steering Pump Sprocket Replacer

Bent Tension Gauge

Pulley Remover

Alternator Pulley Replacer

Pressure Testing Gauge Assembly

Bypass and Orifice Gauge

Pump Oil Seal Pilot

Bearing Preload Spanner Wrench

Adjuster Plug Seal Protector

Fixture Adapter Plate

Power Steering Pump Pulley Remover

Front Suspension Bushings Remover and Replacer

Pump Housing Hole Plugging Tool

Pump Shaft Seal Replacer

Pump Shaft Seal Protector

Insulator Remover and Replacer Socket

Lock Spring Installing Hook

Rack Piston Arbor

Adjuster Plug Bearing Remover and Installer

Thrust Bearing Retainer Installer Adapter

Adjuster Plug Seal Installer

Pin Straightness Checking Block

Pin Guide Support

Sector Shaft Seal Installer

Pivot Pin Removerprocarmanuals.com

04-02-01

Rear Axle
—
Removable Carrier Type

04-02-01

PART
4-2
Rear Axle—Removable Carrier Type

COMPONENT INDEX

AXLE HOUSING (Coil Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE HOUSING (Leaf Spring Suspension)

Cleaning and Inspection

Removal and Installation

AXLE SHAFT

Cleaning and Inspection

Removal and Installation

CONVENTIONAL DIFFERENTIAL

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DIFFERENTIAL BEARINGS AND RING

GEAR

Adjustment

Cleaning and Inspection

Removal and Installation

DIFFERENTIAL CARRIER

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

LIMITED SLIP DIFFERENTIAL

Cleaning and Inspection

Description

Disassembly and Overhaul

Removal and Installation

PILOT BEARING

Cleaning and Inspection

Removal and Installation

PINION AND RING GEAR

Cleaning and Inspection

Removal and Installation

PINION BEARING

Cleaning and Inspection

Removal and Installation

PINION BEARING RETAINER

Cleaning and Inspection

Removal and Installation

PINION SPACER (Collapsible)

Removal and Installation

PINION OIL SEAL

Removal and Installation
MODEL APPLICATION
All
Models

01-10

02-04

01-10

02-13

02-08

02-19

01-10

02-19

01-10

02-13

02-08

01-10

02-03

02-13

02-13

01-10

02-15

01-10

02-15

01-10

02-15

01-10

02-15

02-04
J

01-09

02-08

N/A

N/A

02-17
Mercury
01-09

02-08

N/A

N/A

N/A
Meteor
01-09

02-08

N/A

N/A

02-17
Cougar
N/A

N/A

01-09

02-11

02-17
Fairlane
N/A

N/A

01-09

02-11

02-17
Falcon
N/A

N/A

01-09

02-11

02-17
Montego
N/A

N/A

01-09

02-11

02-17
Mustang
N/A

N/A

01-09

02-11

02-17
Lincoln-
Continental
N/A

N/A

01-09

02-11

N/A
Thunderbird
01-09

02-08

N/A

N/A

N/A
Continental-
Mark
III
01-09

02-08

N/A

N/A

N/A

A page number indicates that the item is
for
the vehicle listed
at
the head
of
the column.

N/A indicates that the item is not applicable
to
the vehicle listed.
procarmanuals.com

04-02-08
Rear Axle — Removable Carrier Type

04-02-08

REMOVAL AND INSTALLATION

CARRIER ASSEMBLY

REMOVAL

1.
Raise the vehicle on a hoist and

remove the two rear wheels and tires.

2.
Remove the two brake drums (3

Tinnerman nuts at each drum) from

the axle shaft flange studs. If diffi-

culty is experienced in removing the

drums, remove the brake adjuster

knockout slug or rubber plug (if so

equipped) and back off the brake

shoes.

3.
Working through the hole pro-

vided in each axle shaft flange, re-

move the nuts that secure the rear

wheel bearing retainer plate. Pull each

axle shaft assembly out of the axle

housing using axle shaft remover,

Tool 4235-C. (Fig. 4). Care must be

exercised to prevent damage to the

production-type synthetic oil seal, if so

equipped. Any roughing or cutting of

the seal element during removal or in-

stallation can result in early seal fail-

ure.
Install a nut on one of the brake

backing plate attaching bolts to hold

the plate to the axle housing after the

shaft has been removed. Whenever a

rear axle shaft is replaced, the wheel

bearing oil seals must be replaced.

Remove the seals with tool 1175AB.

4.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position at as-

sembly. Disconnect the drive shaft at

the rear axle U-joint. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their orig-

inal position relative to the flange

when they are assembled. Remove the

drive shaft from the transmission ex-

tension housing. Install an oil seal re-

placer tool in the housing to prevent

transmission leakage. Refer to the

transmission group for the appropriate

tool.

5.
Clean area around carrier to

housing surfaced with a wire brush and

wipe clean, to prevent dirt entry into

the housing. Place a drain pan under

the carrier and housing, remove the

carrier attaching nuts, and drain the

axle.
Remove the carrier assembly

from the axle housing.

INSTALLATION

Synthetic production-type wheel

bearing seals must not be cleaned,

soaked or washed in cleaning solvent.

1.
Clean the axle housing and

shafts using kerosene and swabs. To

avoid contamination of the grease in
the sealed ball bearings, do not allow

any quantity of solvent directly on the

wheel bearings. Clean the mating sur-

faces of the axle housing and carrier.

2.
Position the differential carrier

on the studs in the axle housing using

a new gasket between carrier and

housing. Install the carrier-to-housing

attaching nuts, and torque them to

specifications.

3.
Remove the oil seal replacer tool

from the transmission extension hous-

ing. Position the drive shaft so that

the front U-joint slip yoke splines to

the transmission output shaft.

4.
Connect the drive shaft to the

axle U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

5.
If the synthetic, production-type

wheel bearing seals were replaced with

service-type leather seals, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the rear axle housing with one of the

tools shown in Figs. 10 and 12.

Tool

T65F-1177.A

E 1571-A

FIG. 12—Rear Axle Shaft Bearing

Seal Installation

6. Install the two axle shaft assem-

blies in the axle housing. Care must

be exercised to prevent damage to the

oil seals. The shorter shaft goes into

the left side of the housing.

Carefully slide the axle shaft into

the housing so that the rough forging

of the shaft will not damage the oil

seal. Start the axle splines into the

differential side gear, and push the

shaft in until the bearing bottoms in

the housing.
7.
Install the bearing retainers on

the attaching bolts on the axle housing

flanges. Install the nuts on the bolts

and torque to specifications.

8. If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1 and install rubber

plugs in the adjuster slots.

9. Install the two rear brake drums

and the drum Tinnerman nuts.

10.
Install the rear wheels and tires.

11.
Fill the rear axle with specified

lubricant.

AXLE HOUSING (COIL

SPRING SUSPENSION)

REMOVAL

1.
Remove the carrier assembly

from the axle housing as outlined in

Differential Carrier Removal and In-

stallation.

2.
Position safety stands under the

frame rear members, and support the

axle housing with either a floor jack

or hoist.

3.
Disengage the brake line from

the clips that retain the line to the

axle housing.

4.
Disconnect the vent tube from

the rear axle housing.

5.
Remove the brake backing plate

assemblies from the axle housing, and

support them with wire. Do not dis-

connect the brake line.

6. Disconnect the lower studs of the

two rear shock absorbers from the

mounting brackets on the axle housing

(Fig. 13 and 14).

7.
Remove the attaching nut and

washer, and disconnect the track bar

from the mounting stud on the axle

housing bracket.

8. Lower the axle housing until the

coil springs are released. Lift out the

coil springs and insulators.

9. Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

10.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and the two eccentric washers (Fig.

13 and 14).

11.
Lower the axle housing and re-

move it from under the vehicle.

INSTALLATION

1.
Transfer the track bar mounting

stud from the old to the new housing.procarmanuals.com

REAR SPRING

5560

VENT

TUBE

INDENT TOWARD

FRONT OF VEHICLE
UPPER ARM

5500

LEFT ARM INDENTED

BY 2 NOTCHES IN BUSHING FLANGE

F 1353-A

f/Q.
J3—Rear Axle Installation—Typical Coil Spring Suspensionprocarmanuals.com

04-02-11
Rear Axle — Removable Carrier Type

04-02-11

If the axle housing is new, install a

new vent. The hose attaching portion

must face toward the front of the ve-

hicle.

2.
If leather-type wheel bearing ser-

vice seals are to be installed, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the axle housing with one of the tools

shown in Fig. 10 and 12.

3.
Position the replacement axle

housing under the vehicle, and raise

the axle with a hoist or floor jack.

Connect the suspension lower arms to

their mounting brackets on the axle

housing with pivot bolts and nuts. Do

not tighten the bolts and nuts at this

point.

4.
Position the suspension upper

arm in its mounting bracket on the

axle housing, and install the adjusting

bolt, eccentric washers, lock washer

and nut. Leave the bolt and nut loose

at this point.

5.
Position the brake lines to the

axle housing, and secure with the re-

taining clips.

6. Install the brake backing plates

on the axle housing flanges.

7.
Connect the track bar to the

mounting stud, install the washer and

attaching nut, and torque to specifica-

tions.

8. Position the rear coil springs and

insulators in the pockets provided.

9. Connect the lower studs of the

two rear shock absorbers to the

mounting brackets on the axle hous-

ing. Install the attaching nuts, and

torque to specifications.

10.
Connect the vent tube to the

vent on the housing. If axle housing is

new, install a new vent.

11.
Clean the mating surfaces of

the axle housing and differential car-

rier. Position the carrier on the

mounting studs on the housing using a

new gasket between carrier and hous-

ing. Install the copper washers and the

carrier-to-housing attaching nuts, and

torque to specifications.

12.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, and

then raise the axle assembly to con-

trolled curb height (Fig. 15). Hold the

axle at controlled curb height by plac-

ing blocks or pieces of steel pipe be-

tween the axle housing and the bumper

rear screw on the side rail. (See speci-

fications for dimensions.)
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG. 75 -Axle Normal Curb

Height and Controlled Height

for Arm Installation

13.
With the axle at controlled curb

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm-to-axle housing pivot bolts

and nuts to specifications.

14.
Remove the oil seal replacer

tool from the transmission extension

housing. Position the drive shaft so

that the front U-joint slip yoke splines

to the transmission output shaft.

15.
Connect the drive shaft to the

U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

16.
Carefully slide the two axle

shaft assemblies in the axle housing.

The shorter shaft goes into the left

side of the housing. Use care in slid-

ing the axle shafts into the housing so

that the rough forging of the shaft will

not damage the oil seal. Start the axle

splines into the differential side gear,

and push the shaft in until the rear

wheel bearing bottoms in the housing.

17.
Install the rear wheel bearing

retainers on the attaching bolts on the

axle housing flanges. Install the nuts

on the bolts and torque to specifica-

tions.

18.
If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1, and install rubber

plugs in the adjuster slots.

19.
Install the two rear brake

drums and the drum attaching (Tin-

nerman) nuts.

20.
Install the rear wheels and tires.

21.
Fill the rear axle to the bottom

of the filler plug hole located in either

the carrier casting or housing cover

with specified lubricant. Be sure that

the axle is in operating position.

22.
Road test the vehicle to be sure

that pinion and driveshaft angles are
correct. Any shudder during heavy ac-

celeration, or deceleration may require

a pinion and driveshaft angle re-

adjustment as detailed in Driveshaft

and Pinion Angle Adjustment, Group

3,
Part 3-2.

AXLE HOUSING (LEAF

SPRING SUSPENSION)

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly. Disconnect

the drive shaft at the drive pinion

flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in

Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-

fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tool shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with

mechanic's wire. The hydraulic brake

lines and the parking brake cables are

still attached to the brake backing

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 16).

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operation*.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install theprocarmanuals.com

04-04-04
Rear Axle — Ford Light-Duty (WER)

04-04-04

REMOVAL AND INSTALLATION

AXLE HOUSING

Refer to Fig. 7.

REMOVAL

1.
Raise the vehicle on a hoist.

2.
Remove the wheels and tires

from the brake drums.

3.
Position a drain pan and loosen

the rear axle cover to housing attach-

ing bolts. Drain the housing.

4.
Remove the attaching (Tinner-

man) nuts that secure the brake drums

to the axle shaft flanges, and then re-

move the drums (Fig. 7).

5.
Remove the axle housing cover

bolts,
cover and gasket. Discard the

gasket. Remove the drain pan.

6. Disconnect the drive shaft at the

drive pinion companion flange. Re-

move the drive shaft from the trans-

mission extension housing. Install an

oil seal replacer tool in the transmis-

sion housing to prevent leakage. Refer

to the transmission group for the ap-

propriate tool.

7.
Disconnect the lower end of the

shock absorbers at the mounting

brackets.

8. Disconnect the track bar from

the axle housing stud. If the axle

housing is to be replaced, transfer the

stud to the new housing.

9. Position safety stands under the

rear frame members. Lower the vehi-

cle with the hoist and allow the axle

to lower far enough to relieve rear

spring tension.

10.
Remove the pinion shaft lock

bolt and pinion shaft (Fig. 2), differ-

ential pinion gears and thrust washers.

11.
Push the axle shaft(s) inward

toward the center of the axle housing.

Remove the C-locks from the inner

ends of the axles (Fig. 3). Remove the

axle shafts from the housing. Extreme

care must be used to avoid contacting

the axle shaft seal lip with any portion

of the axle shaft other than the seal

journal.

12.
Disconnect the vent hose from

the rear vent tube and remove all

brake lines from the axle housing re-

taining clips.

13.
Remove the brake backing

plate attaching nuts and the plates

from the axle housing. Suspend the

plates above the axle housing with

mechanics wire. The hydraulic brake

lines and the parking brake cables will

remain attached to the brake backing

plates.
14.
Support the rear axle housine

on a jack.

15.
Remove the right and left rear

springs and insulators.

16.
Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

17.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and two eccentric washers.

18.
Lower the rear axle to the floor

with the jack and remove the axle

from under the vehicle.

19.
Remove the wheel bearings and

oil seals with the tool shown in Fig. 4.

20.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. Refer

to Section 4, Major Repair Operation

for the procedure.

INSTALLATION

1.
Lightly coat the wheel bearing

rollers with axle lubricant. Install

wheel bearings in the axle housing

with the tool shown in Fig. 5. The

bearings should seat firmly against the

shoulder.

2.
Wipe all lubricant from the oil

seal bore before installing the seal. If

axle housing is being replaced, new

seals must be installed.

3.
Inspect the original seal for

nicks,
scuffs or abnormal wear, and

replace if necessary. New seals are

pre-packed with lubricant and do not

require an oil soak.

4.
Install the seal with the tool

shown in Fig. 6. Installation without

the use of the proper tool will distort

the seal and cause leakage.

5. Raise the rear axle into position

under the vehicle with a hoist or floor

jack. Connect the suspension lower

arms to their mounting brackets on

the axle housing with pivot bolts and

nuts.
Do not tighten the mounting

bolts at this point.

6. Position the suspension upper

arm in its mounting bracket on the

axle housing and install the adjusting

bolt, eccentric washers, lock washer

and nut. Do not tighten the mounting

bolt at this point.

7.
Place the rear coil springs and

insulators into position in the pockets

provided.
8. Place the brake backing plates

on the axle housing flanges, install 4

attaching bolts and nuts and torque

them to specifications.

9. Position the brake lines to the

axle housing and secure them with the

retaining clips. If the axle housing is

new, install a new vent. When install-

ing the new axle vent apply a small

amount of Locktite (C5AZ-19554-B)

to prevent oil leakage between vent

and axle housing. Connect the vent

tube to the vent.

10.
Install the pinion side gears and

thrust washer.

11.
Slide the axle shafts into place

in the axle housing. Exercise care that

splines or any portion of the axle

shafts do not damage the oil seals and

that they engage with the splines of

the differential side gears.

12.
Install the axle shaft C-lock O-

ring and C-lock on the inner end of

the shaft and push the shaft outward

so that the shaft lock seats in the

counterbore of the differential side

gear.

13.
Position the pinion differential

gears and thrust washers 180 degrees

apart to the differential side gears.

Revolve the gear assembly until the

holes in the differential case are al-

igned with the pinion gears.

14.
Position the differential pinion

shaft through the case and pinions, al-

igning the hole in the shaft with the

lock bolt hole. Install the lock bolt

and tighten it to specification.

15.
Clean the gasket mounting sur-

face of the rear axle housing and the

cover. Install a new cover gasket,

cover and the attaching bolts. Torque

the bolts to specification.

16.
Raise the rear axle on a hoist

and remove the safety stands.

17.
Connect the track bar to the

mounting stud. Install the washer and

nut. Torque the nut to specification.

18.
Connect the two rear shock ab-

sorbers to the mounting brackets on

the axle housing and torque the at-

taching nuts to specification.

19.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, then

raise the axle assembly to the con-

trolled height (Fig. 8). Hold the axle

at the controlled height by placing

blocks or pieces of steel pipe between

the axle housing and the bumper rear

screw on the side rail.procarmanuals.com

04-04-06
Rear Axle — Ford Light-Duty (WER)

04-04-06

20.
With the axle at controlled

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm to axle housing pivot bolts

and nuts to specifications.

21.
Remove the oil seal replacer

from the transmission extension hous-

ing. Install the drive shaft in the ex-

tension housing. Align the scribe

marks on the cups, flange and drive

shaft and connect the drive shaft at

the drive pinion flange. Torque the at-

taching bolts to specification
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG.8—
Axle
Normal Curb Height

and Controlled Height for Arm

Installation
22.
Install the brake drum and at-

taching (Tinnerman) nuts.

23.
Install the wheel and tire on the

brake drum. Install the wheel covers.

24.
Adjust the drive shaft and pin-

ion angle to specification.

25.
Add the amount of specified lu-

bricant required to reach to the bot-

tom of the filler plug hole. Make sure

the rear axle is in running position.

Install the filler plug and torque it to

specification.

26.
Lower the vehicle.

4 MAJOR REPAIR OPERATIONS

DISASSEMBLY OF AXLE
The rear axle components are

shown in Fig. 9.

DIFFERENTIAL SIDE GEAR

AXLE SHAFT C-WASHER \

DIFFERENTIAL PINION SHAFT

THRUST WASHER

BEARING ASSEMBLY

CUP
THRUST WASHER

^^ DIFFERENTIAL PINION GEAR

BEARING ADJUSTING NUT

DIFFERENTIAL

PINION SHAFT

LOCK BOLT

LOCK WASHER
BOLT

LOCK WASHER

ADJUSTING NUT LOCK

DRIVE GEAR ATTACHING BOLT

BEARING CAP

AXLE HOUSING ASSEMBLY

PINION AND RING GEAR

PINION LOCATING SHIM(S)

BEARING CUP

BOLT

NUT

BEARING CUP

COLLAPSIBLE SPACER

AXLE SHAFT

E 1572-C

FIG. 9—Disassembled Light-Duty (WER) Rear Axleprocarmanuals.com

04-05-05
Specifications

04-05-05

SPECIAL TOOLS

FORD MERCURY, METEOR (Continued)

Ford Tool No.

T57L-4221-A1 or

Tool-4222-K

TOOL 6565-AB

TOOL 6565

TOOLS 4201-C

andD

TOOL-T57L-

4067-A

TOOL-T50T-100-A

T00L-T66L-

12132-B

CJ-6625 (Snap-

On)
Foniisr
NO.

4222-H

6565-AB

6565

4201-C

4067-B

—

—

—
Description

Differential Bearing Installer

Adapter

Dial Indicator

Differential Backlash and Runout

Gauge with Universal Bracket, Dial

Indicator and Bracket

Differential Bearing Adjuster Wrench

Impact Hammer-Long

Adapter

Puller
Ford Tool No.

TOOL-T60K-

7697-B

T00L-T65F-

1177-A

T00L-T65L-

4851-A

TOOL-OTC-951

T00L-T67P-

4616-A

TOOL-T53T-

4621-C
Fomor No.

—

—

—

—

—
Description

Transmission Extension Housing

Bushing Repiacer

Rear Wheel Bearing Oil Seal Repiacer

Flange (Universal Joint) Axle End

Remover

Universal Puller

Pinion Bearing Cups Repiacer

Pinion Bearing Cone Repiacer

COUGAR, FAIRLANE, FALCON,

Ford Tool No.

T50T-100-A

T58L-101-A

T62L-201-A

T56L-400-A

T57L-500-A

T00L-1175-AB

T50T-100-Aand

TOOL-1175-AB

T60K-1177-B

T60K-1225-Aor

T00L-1225-C

TOOL-1225-B

T00L-T54-P-

3044-A

T00L-T57L-

4067-A

T57L-4067-Aor

T60K-4067-A

TOOL-4201-C

andD

T65K-4204A or

T59L-4204-A

T00L-4221-AL

T57L-4221-A

T00L-4222-H

T66L-4235-A
Former No.

B-160

-

4851-A

-

1175-AB

1175-AE

1177-B

4067-B

4221 or

4211-A

4201-C

4067-E

4221-AL

4222-K

4222
MONTEGO, MUSTANG

Description

Impact Hammer

Puller Attachment

Handle Adapter

Puller

Bench Mounted Holding Fixture

Grease Seal Remover (Head Only)

Seal Remover

Rear Wheel Bearing Oil Seal

Axle Shaft Bearing Remover and Repiacer

Axle Shaft Searing Remover

Axle Shaft Bearing Repiacer

Front Suspension Upper and Lower Arm

Overhaul Tool Kit

Differential Bearing Adjuster Nut

Wrench

Limited-Slip Differential Check

Differential Backlash and Runout Gauge

With Universal Bracket, Dial Indicator

and Bracket

Differential Bearing Adjuster Nut

Wrench

Differential Bearing Cone Remover

Pilot (Use with T00L-4221C or

T00L-4851-A)

Differential Bearing Cone Repiacer

Differential Bearing Cone Repiacer

Rear Axle Shaft Assembly Remover

Adapter
Ford Tool No.

T57L-4614-A

T00L-4615-J

T60K-4616-A

T57L-4616-A

T57L-4616-A2

T55P-4616-A2

T00L-4621-K

T62F-4621A

T62F-4625-A

T55P-4676-A

T62F4676A

T53T-4851A

T57L-4851-A

T00L-4858-E

T65K-4204-A

T59L-4204-A

T00L-6565-AB

TOOL-6565
Former No.

4614

4615-J

4615-HF

4625-HR

4615-
E

andP

4615-
E

andF

-

4621-K

4625-AC

land 2

4676-G

4676-
H

4851-A

4858-D

4851-K

4858-
E

—

44211 and

44211-A

6565-AB

6565
Description

Drive Pinion and Drive Pinion Retainer

Assembly Support

Drive Pinion Front Bearing Cup Remover

Pinion Bearing Cup Repiacer

Pinion Front Bearing Cup Remover

Pinion Front Bearing Cup Repiacer

Pinion Rear Bearing Cup Repiacer

Drive Pinion Rear Bearing Cone Remover

Pinion Bearing Cone Repiacer

Drive Pinion Pilot Bearing Remover

and Repiacer

Drive Pinion Oil Seal Repiacer

Drive Pinion Oil Seal Repiacer

Flange (Universal Joint) Axle End

Remover

Universal Joint Flange Holder

Companion Flange and Pinion Bearing

Repiacer

Limited-Slip Differential Torque Check

Adapter

Locking Differential Torque Check

Adapter

Dial Indicator

T68P-4946-A - Traction-Lok Shim Template Toolprocarmanuals.com